Collating system

Abstract

A co-mailing system uses an insert machine to merge different mail streams into one stream in the sequence of a master mail list. By using an insert machine with vertically oriented pockets traveling on a moving conveyor, the speed of merging the mail streams is high and efficiency is obtained.

What is claimed is: 
     
       1. A method comprising:
 providing a master mail list having a sequence of mail recipients; 
 assembling printed products to form a first mail stream, wherein assembling is conducted by placing a single folded sheet each by folded sheet feeders on an assembly chain, by gathering the individual folded sheets on top of another and transporting them to a stitcher station, by stitching said gathered folded sheets to form a printed product, by transferring said printed product to a trimmer for forming a trimmed product, by passing said trimmed product to a printer and printing address indicia on the product for forming the first mail stream; 
 feeding the printed products from the first mail stream into moving vertical pockets of an insert machine; 
 providing a second mail stream of printed products to the insert machine; and 
 feeding the printed products from the second mail stream into the moving vertical pockets to combine the first and second mail streams in the sequence of the master list. 
 
     
     
       2. The method of  claim 1 , further comprising:
 printing address indicia on the printed products of at least one of the first and the second mail stream. 
 
     
     
       3. The method of  claim 1 , wherein
 the first mail stream is assembled using an assembling machine. 
 
     
     
       4. The method of  claim 3 , wherein
 the insert machine is one of a straight line insert machine and a rotary insert machine. 
 
     
     
       5. The method of  claim 1 , wherein
 a shuttle transfers the first mail stream from the assembling machine to the insert machine. 
 
     
     
       6. The method of  claim 1 , wherein
 the insert machine has a first feeder for feeding the printed products from the first mail stream into the moving vertical pockets and a second feeder for feeding the printed products of the second mail stream into the moving vertical pockets. 
 
     
     
       7. The method of  claim 2 , wherein
 at least one of the first feeder and the second feeder further comprises a printer for printing address indicia on the printed products before feeding the printed products into the moving vertical pocket. 
 
     
     
       8. The method of  claim 1 , wherein
 the printed products from the second mail stream are fed to moving vertical pockets that contain the printed products from the first mail stream so as to combine printed product from the first and second mail streams in the same pocket. 
 
     
     
       9. The method of  claim 1 , wherein
 the printed product from the second mail stream is fed to an empty moving vertical pocket that is adjacent and subsequent to the pocket containing printing product from the first mail stream. 
 
     
     
       10. The method of  claim 1 , further comprising:
 providing a third mail stream of printed product to the insert machine; and 
 feeding the printed products from the third mail stream to the moving vertical pocket to combine the first, second, and third mail streams in the sequence of the master list. 
 
     
     
       11. The method of  claim 10 , wherein
 the third mail stream is provided to the insert machine downstream of the second mail stream. 
 
     
     
       12. The method of  claim 1 , further comprising:
 packaging the combined mail streams. 
 
     
     
       13. The method of  claim 1 , wherein
 a first controller controls the assembly of the first mail stream; and 
 a second controller controls merging of mail streams on the insert machine. 
 
     
     
       14. A method comprising:
 providing a master mail list having a sequence of mail recipients; 
 assembling printed products to form a first mail stream using an assembling machine, wherein assembling is conducted by placing a single folded sheet each by folded sheet feeders on an assembly chain, by gathering the individual folded sheets on top of another and transporting them to a stitcher station, by stitching said gathered folded sheets to form a printed product, by transferring said printed product to a trimmer for forming a trimmed product, by passing said trimmed product to a printer and printing address indicia on the product for forming the first mail stream; 
 transferring the first mail stream to a shuttle and delivering the first mail stream by the shuttle to a first feeder of an insert machine; 
 feeding the printed products from the first mail stream into moving vertical pockets of the insert machine using the first feeder; 
 providing a second mail stream of printed products to a second feeder the insert machine; and 
 feeding the printed products from the second mail stream into the moving vertical pockets using the second feeder to combine the first and second mail streams in the sequence of the master list. 
 
     
     
       15. The method of  claim 14 , further comprising:
 printing address indicia on the printed products of at least one of the first and the second mail stream. 
 
     
     
       16. The method of  claim 14 , wherein
 the insert machine is one of a straight line insert machine and a rotary insert machine. 
 
     
     
       17. The method of  claim 14 , wherein
 at least one of the first feeder and the second feeder further comprises a printer for printing address indicia on the printed products before feeding the printed products into the moving vertical pocket. 
 
     
     
       18. The method of  claim 14 , wherein
 the printed products from the second mail stream are fed to moving vertical pockets that contain the printed products from the first mail stream so as to combine printed product from the first and second mail streams in the same pocket. 
 
     
     
       19. The method of  claim 14 , wherein
 the printed product from the second mail stream is fed to an empty moving vertical pocket that is adjacent and subsequent to the pocket containing printing product from the first mail stream. 
 
     
     
       20. The method of  claim 14 , further comprising:
 providing a third mail stream of printed product to the insert machine; and 
 feeding the printed products from the third mail stream to the moving vertical pocket to combine the first, second, and third mail streams in the sequence of the master list. 
 
     
     
       21. The method of  claim 20 , wherein
 the third mail stream is provided to the insert machine downstream of the second mail stream. 
 
     
     
       22. The method of  claim 14 , further comprising:
 packaging the combined mail streams. 
 
     
     
       23. The method of  claim 14 , wherein
 a first controller controls the assembly of the first mail stream; and 
 a second controller controls merging of mail streams on the insert machine.